AdeptOne Robot

User’s Guide

■ ■ ■

PRELIMINARY

VERSION

i

AdeptOne User’s Guide

The information contained herein is the property of Adept Technology, Inc. and shall not be reproduced in whole or in part without prior written approval of Adept

Technology, Inc. The information herein is subject to change without notice and should not be construed as a commitment by Adept Technology, Inc. This manual is periodically reviewed and revised.

Adept Technology, Inc. assumes no responsibility for any errors or omissions in this document. Critical evaluation of this manual by the user is welcomed. Your comments assist us in preparation of future documentation. A form is provided at the back of the manual for submitting your comments.

Copyright © 1991 by Adept Technology, Inc. All rights reserved.

The Adept logo is a registered trademark of Adept Technology, Inc.

Adept, Adept CC and MC, AdeptVision, AdeptOne, V and V

+ are trademarks of

Adept Technology, Inc.

Printed in the United States of America ii

Table of Contents

TABLE OF CONTENTS

CHAPTER 1 GENERAL INFORMATION............................................................. 1

1.1 This Manual and Related Publications............................................................1

1.2 Notes, Cautions, and Warnings........................................................................1

Orientation......................................................................................................2

Controller High Power Indicator ................................................................2

1.3 Customer Service Assistance ............................................................................2

Service Calls....................................................................................................2

Training Information.....................................................................................3

Application Information...............................................................................3

International Customer Assistance .............................................................3

1.4 Safety ....................................................................................................................3

System Safeguards.........................................................................................4

Equipment Safety...........................................................................................4

Acceptable Modifications ............................................................................5

Unacceptable Modifications ........................................................................5

CHAPTER 2 OVERVIEW .......................................................................................... 7

2.1 Description...........................................................................................................7

General ............................................................................................................7

Joint Motions ..................................................................................................7

Joint 1 .........................................................................................................7

Joint 2 .........................................................................................................7

Joint 3 .......................................................................................................10

Joint 4 ......................................................................................................10

Limiting Joint Travel ...................................................................................11

Softstops...................................................................................................11

Hardstops ................................................................................................11

Brakes ...........................................................................................................12

2.2 Dimensions ........................................................................................................14

2.4 Options ...............................................................................................................17 iii

AdeptOne User’s Guide

CHAPTER 3 INSTALLATION ............................................................................... 19

3.1 Environmental and Facility Requirements ...................................................19

Facility Ambient Air Quality .....................................................................19

Compressed Air ...........................................................................................19

Electrical........................................................................................................20

Robot Workcell Free Space.........................................................................20

Floor...............................................................................................................20

Mounting Surface ........................................................................................20

Plate..........................................................................................................23

Spool.........................................................................................................23

3.2 Tool and Equipment Requirements ...............................................................24

3.3 Unpacking and Inspection ..............................................................................25

Before Unpacking ........................................................................................25

Upon Unpacking..........................................................................................25

Repacking For Relocation...........................................................................25

3.4 Preparation For Installation ............................................................................26

3.5 Installing a Mounting Plate.............................................................................26

3.6 Installing a Mounting Spool............................................................................28

Robot to Controller ......................................................................................31

Connecting Compressed Air Supply ........................................................31

3.9 Compressed Air Lines In the Robot...............................................................32

Solenoid Valve Assembly ..........................................................................32

User Air Lines ............................................................................................33

Spare Air Line ..............................................................................................33

Clamp-mounted End-Effector ...................................................................34

Screw-mounted End-Effector.....................................................................35

3.11 User Signal and Voltage Lines........................................................................38

USR1 Through USR5 ...................................................................................38

Spare Solenoid Drivers ...............................................................................38

DC Power......................................................................................................40

Optional -12 VDC Procedure .....................................................................41

3.12 Outer Link Mounting Holes ..........................................................................42

CHAPTER 4 MAINTENANCE................................................................................ 43

4.1 Introduction.......................................................................................................43

Lubricating the Upper Quill Shaft ............................................................43

Lubricating the Lower Quill Shaft ...........................................................45

4.3 Draining Moisture from the Air Filter...........................................................45

4.4 Check Mounting Bolt Tightness .....................................................................46 iv

Table of Contents

APPENDIX A FIFTH AXIS OPTIONS .................................................................. 47

A.1 Introduction.......................................................................................................47

Fifth Axis Option .........................................................................................47

Pneumatic End-Effector..............................................................................47

A.2 Specifications.....................................................................................................47

A.3 Installation .........................................................................................................48

A.4 Operation ...........................................................................................................48

Installing End-effectors...............................................................................48

J5 User Cable Connector.............................................................................48

Programming Information .........................................................................49

A.5 Maintenance and Troubleshooting ................................................................50

Checking Flange Position ...........................................................................50

INDEX........................................................................................................................... 51

LIST OF FIGURES

Figure 2-1. AdeptOne Robot Joint Locations ...................................................................8

Figure 2-2. Joint 1 Motion ...................................................................................................9

Figure 2-3. Joint 2 Motion ...................................................................................................9

Figure 2-4. Joint 3 and Joint 4 Motion .............................................................................10

Figure 2-5. Robot base showing brake release button ..................................................13

Figure 2-6. Dimensional Overview .................................................................................14

Figure 2-7. AdeptOne Robot Working Envelope ..........................................................15

Figure 3-1. AdeptOne with Calibration Fixture ............................................................21

Figure 3-2. Mounting Hole Pattern (Robot-to-Plate/Spool)........................................22

Figure 3-3. Mounting Hole Pattern (Plate/Spool-to-Floor) .........................................22

Figure 3-4. Recommended Mounting Spool Specifications ........................................24

Figure 3-5. Mounting Plate-to-Floor Installation Detail...............................................27

Figure 3-6. Mounting Spool-to-Floor Installation Detail..............................................29

Figure 3-7. Robot Base Showing Air Filter and Cable Connector Locations.............31

Figure 3-8. User Connections in the Robot.....................................................................32 v

AdeptOne User’s Guide

LIST OF FIGURES (continued)

Figure 3-9. Clamp-mounted End-Effector Installation.................................................34

Figure 3-10. Screw-mounted End-Effector Installation ..................................................35

Figure 3-11. Quill Flange Dimensions...............................................................................37

Figure 3-12. User Connector Location on the Tower Assembly ...................................39

Figure 3-13. User Option Jumper Header on OLC..........................................................41

Figure 3-14. Mounting Holes on Top Side of Outer Link...............................................42

Figure 4-1. Upper Quill Shaft ...........................................................................................44

Figure 4-2. Lower Quill Shaft and Lip Seal Location....................................................45

Figure A-1. Fifth-Axis End Effector Mounting Details..................................................49

LIST OF TABLES

Table 2-1.

Table 2-2.

Table 3-1.

Softstop and Hardstop Specifications .........................................................12

Performance Specifications...........................................................................16

User Air Line Command Summary.............................................................33

Table 3-2.

Table 4-1.

Tower User Connector Pinouts ....................................................................40

Recommended AdeptOne Preventive Maintenance Schedule ..............46

Table A-1. Fifth Axis Specifications................................................................................47

Table A-2. J5 User Cable Connector Pin Identification................................................48 vi

CHAPTER 1 GENERAL INFORMATION

1.1 This Manual and Related Publications

This manual provides general, installation, and maintenance information for the AdeptOne robot, also referred to as a Selective Compliance

Assembly Robot Arm, or SCARA.

The following Adept publications are referenced in this manual:

• V and V+ Reference Guide

•

Instructions for Adept Utility Programs

•

Adept MC Controller User's Guide

•

Adept CC Controller User's Guide

• User's Guides for options purchased with the robot.

Throughout this manual you will find references to the V or V

+

operating system and control language. V

+

is Adept’s advanced operating system and control language, which offers additional capabilities over the V system.

1.2 Notes, Cautions, and Warnings

There are three levels of special notation used in this equipment manual.

In descending order of importance, they are:

WARNING

If the actions indicated in a “WARNING” are not complied with, injury or major equipment damage could result. A Warning statement will typically describe the potential hazard, its possible effect, and the measures that must be taken to reduce the hazard.

CAUTION

If the action specified in the “CAUTION” is not complied with, damage to your equipment could result.

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AdeptOne User’s Guide

NOTE

A “NOTE” provides supplementary information, emphasizes a point or procedure, or to gives a tip for easier operation.

Orientation

Throughout this text descriptive words such as "right," "left," "top," and

"bottom" will be used to locate items. Whenever these terms appear they are oriented from the standard operator's position as though facing the front of the unit, for example, "right" is that portion of the system to the operator's right, etc.

Controller HIGH POWER Indicator

On the Adept CC controller front panel there is an amber indicator light labeled

HIGH POWER

; on the Adept MC controller the same indicator is labeled

ARM POWER

. Any reference in this manual to

HIGH POWER

also refers to

ARM POWER.

1.3 Customer Service Assistance

Service Calls

Adept Technology maintains fully staffed Customer Service Centers at its headquarters in San Jose, CA, and in Dortmund, Germany. The dedicated phone lines for service calls are:

(800) 232-3378 from outside California

(800) 232-3379 from within California

(408) 434-5000 from Canada, Latin America, Asia/Pacific region

(49) 231 / 75 89 40 from Europe

When calling Customer Service, please have the unit's serial number available. The serial number is located on the label on the base of the robot (refer to Figure 2-5).

Training Information

For information regarding Adept Training Courses, please call

(408) 434-5024.

2

Application Information

There is also a dedicated phone line for assistance with software and application questions. For Applications assistance call (408) 434-5033.

International Customer Assistance

For information on training or applications in Europe, call the Adept

Customer Service Center in Dortmund, Germany. The phone number is:

(49) 231 / 75 89 40.

1.4 Safety

The AdeptOne robot may move at high speed and exert considerable force. Like all mechanical systems and most industrial equipment, it must be treated with respect by both the User and the Operator.

NOTE

This manual follows Robotic Industries Association (RIA) definitions of "User" as the responsible person or company and "Operator" as a person who starts, stops, or monitors robot or workcell operation.

This User's Guide should be read by ALL personnel who operate or maintain AdeptOne systems, or who work within, or near, the workcell.

We also recommend you read the American National Standard for

Industrial Robot Systems-Safety Requirements, published by the RIA, in conjunction with the American National Standards Institute (ANSI). The publication, ANSI/RIA R15.06-1986, contains guidelines for robot system installation, safeguards, maintenance, testing, start-up, and operator training. The document is available from:

American National Standards Institute

1430 Broadway

New York, NY 10018

This Guide assumes that the User has successfully completed an Adept

Training Course and has a basic working knowledge of the Adept system. The User should provide the necessary additional training for

ALL personnel working within or around the workcell.

3

AdeptOne User’s Guide

System Safeguards

Safeguards should be an integral part of robot workcell design, installation, Operator training, and operating procedures. Adept systems are computer controlled, and may activate remote devices under program control at times or along paths not anticipated by personnel. It is critical that safeguards be in place to prevent personnel from entering the workcell whenever equipment power is present.

WARNING

Entering the workcell when the Adept controller

HIGH

POWER or

PROGRAM RUNNING

lights are ON could result in severe injury.

Adept Technology highly recommends the use of workcell safety features such as light curtains, safety gates, or safety floor mats to prevent access to the workcell while power is present. Adept Controller systems have various control features which may aid the user in constructing system safeguards, including:

• Emergency stop circuitry

• Digital input and output lines

The emergency power-off circuitry in the controller is capable of switching external power systems, as well as detecting intrusion signals from safety barriers.

Equipment Safety

All personnel must observe sound safety practices during the operation and testing of all electrically powered equipment. To avoid injury or damage to equipment, always remove power by disconnecting the AC power cord from the source BEFORE attempting ANY repair or upgrade activity.

WARNING

DO NOT

remove or replace any assemblies, subassemblies, Printed Circuit Assemblies (PCAs), or components with primary power present. To avoid possible personnel injury or equipment damage, always remove power

BEFORE

attempting repair or upgrade procedures.

4

1.5 Robot Modifications

It is often necessary to make modifications to Adept robots to successfully integrate them into a workcell. Unfortunately, many seemingly simple modifications can either cause a robot failure, or reduce the robot’s performance, reliability, or lifetime.

Acceptable Modifications

In general, the following robot modifications will not cause any problems, but may affect robot performance:

• Attaching tooling, utility boxes, solenoid packs, vacuum pumps, screwdrivers, cameras, lighting, etc. to the inner link, outer link, or column. The total weight of such items on any robot should not exceed 10 pounds. See Chapter 3 for information on four mounting holes (8-32 tapped) on the outer link.

• Attaching hoses, pneumatic lines, or cables to the robot. These should be designed so they do not restrict joint motion or cause robot motion errors.

• Modifying robot access covers as long as adequate protection is provided after the modification. Covers for the quill, inner and outer links, Joint 2, and the robot signature card can be modified, as long as modifications (long screws, etc.) do not extend inside the robot.

Unacceptable Modifications

If not done properly, the modifications listed below will damage the robot, reduce system reliability, or shorten the life of the robot.

CAUTION

Making any of the modifications outlined below will void the warranty of any components that Adept determines were damaged due to the modification. Please contact

Adept Customer Service before attempting any of the following modifications to determine if they can be made without causing problems.

• Modifying any of the robot harnesses or robot to controller cables.

• Modifying any drive system components.

• Modifying, including drilling or cutting, any robot casting.

• Modifying any robot electrical component or PC board other than those explicitly stated in the robot user’s guide.

• Routing additional hoses, air lines, or wires through the robot.

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AdeptOne User’s Guide

NOTES

6

OVERVIEW

2.1 Description

General

The AdeptOne is a four-axis SCARA robot. Joints 1, 2, and 4 are rotational and Joint 3 is translational. Refer to Figure 2-1 for an overview of the robot joint locations. Refer to Figure 2-7 for the operating envelope and Table 2-2 for specifications.

The AdeptOne is designed to interface with either the Adept MC or the

Adept CC controller. All control and operation of the AdeptOne is programmed and performed through the selected controller.

Refer to the user's guide for your particular controller for explicit controller operating instructions. Refer to the V and V

+

Reference Guide for programming instructions. The optional Operator’s or Programmer’s

Pendant is required for manually teaching robot locations. Additionally, it can serve as the sole operator interface to the system.

All physical connections between the AdeptOne robot, its controller, and the facility are located at the rear of the robot base, as shown in Figure 2-

5.

Joint Motions

Joint 1

Joint 1, also referred to as the "shoulder", provides the rotational movement of the inner link and the column. Travel of the inner link is limited by software to 300°. (Refer to Figure 2-2.)

Joint 2

Joint 2, also referred to as the "elbow", is the pivot point between the inner link and the outer link. Outer link travel is limited by hardstops located on top of the inner link. Travel of Joint 2 is limited by software to a total of 294°. This motion can be likened to an elbow capable of acting in either a left- or right-hand configuration. (See Figure 2-3.)

The AdeptOne is capable of attaining a given location utilizing either a right-hand ("Righty") or left-hand ("Lefty") configuration. However,

7

AdeptOne User’s Guide

when V or V

+

moves the arm to a location, it must sometimes make assumptions about which configuration to use. While this generally produces the result desired by the Programmer, sometimes the system assumption may differ from the Programmer's expectations. In those cases, the Programmer must specify (within the program) "Righty" or

"Lefty" operation.

NOTE

For further information concerning right- and left-hand configuration, refer to the chapter entitled, "Robot

Locations" in your V and V

+

Reference Guide.

Figure 2-1. AdeptOne Robot Joint Locations

8

Figure 2-2. Joint 1 Motion

Figure 2-3. Joint 2 Motion and Lefty-Righty Configurations

9

AdeptOne User’s Guide

Joint 3

Joint 3 provides vertical movement of the quill at the end of the outer link, with a standard stroke of 7.7 inches (196 mm). An optional Joint 3 provides a stroke of 11.6 inches (295 mm). (Refer to Figure 2-4.)

Joint 4

Joint 4, also referred to as the “wrist”, provides rotation of the quill over a range of 554°. This motion is similar to that of the human hand involved in tightening a bolt or unscrewing a bottle cap. (Refer to Figure 2-4.)

Figure 2-4. Joint 3 and Joint 4 Motion

10

Limiting Joint Travel

The joint motion or travel is limited by both software and hardware. The programmable software limits are known as softstops; the fixed hardware limits are called hardstops. (See Table 2-1.)

Softstops

The robot controller uses softstops to determine the range of motion it will allow the robot to move under program control, or to be moved by an operator using a manual control pendant. If a robot joint travels beyond a softstop, the controller will automatically shut off

HIGH POWER

(ARM POWER)

, thereby activating the brakes. Furthermore, the controller will not allow the robot power to be turned on while any joint is beyond its softstop. If this situation occurs, use the brake release button (see the section on Brakes later in this chapter) and manually move the arm back within the softstop limits. You can also move the arm back within the softstop limits using the Manual Control Pendant in joint mode.

Under operator control (using the manual control pendant to move the robot) the robot will stop very abruptly when it encounters a softstop.

This abruptness is due to the high-torque motors; there is no hardstop at these locations.

Occasions may arise when it becomes mandatory to limit the travel of one or more of the joints within the normal working envelope. This can be easily accomplished by adjusting softstops using the CONFIG_R utility program, which is supplied with the system.

NOTE

For further information concerning joint travel limitation, refer to the Instructions for Adept Utility Programs manual furnished with your system.

Hardstops

In most cases the softstop will prevent joint travel from contacting a hardstop; however, contact is possible during high-speed operation. The hardstops are designed to withstand large forces without damaging the robot.

The hardstops for each joint are fixed mechanical stops. The hardstops for Joints 1, 3, and 4 are located inside the robot. The hardstops for Joint

2 are mounted externally on the inner link; they are the hard rubber cylinders that the large eye bolts pass through (Figure 2-3). The hardstops for Joint 3 are mounted at the top and bottom of the quill. The

Joint 2 and 3 hardstops must not be modified in any way or damage to the robot could occur.

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AdeptOne User’s Guide

Table 2-1. Softstop and Hardstop Specifications

Joint 1

Joint 2

Joint 3

Standard

Joint 3

Optional

Joint 4

±150°

±147°

0.1 to 7.8"

(2.5 to 197.5 mm)

0.1 to 11.6”

(2.5 to 297.5 mm)

±277°

±152° (Braketrack)*

±300° (Hardstop)

±149.5°

-0.1 to 7.9"

(-2.5 to 202 mm)

-0.1 to 11.9"

(-2.5 to 302 mm)

±280°

*

In between the softstop and hardstop, Joint 1 has a “braketrack.” An internal proximity sensor will cause a V/V

+

error condition and shutdown HIGH POWER to the robot if the braketrack area is entered. Use the brake release button to move the arm out of the braketrack and clear the error condition.

Brakes

The AdeptOne has "fail-safe" spring-actuated air release brakes on Joints

1, 2, and 3. These brakes are on whenever

HIGH POWER (ARM POWER)

is off . The brakes are intended primarily to restrict arm movement when high power is off, but they also assist in stopping robot motion when the

Emergency Stop circuitry is activated or when there is a robot motion error. These brakes are not designed to be used as a routine method of stopping robot motion.

Under some circumstances you may want to manually position the arm without turning on

HIGH POWER

. For such instances, a "brake-release" button is located on the rear of the base (see Figure 2-5). When system power is on, pressing the button releases the brakes, which allows movement of the arm. If this button is pressed while

HIGH POWER

is on,

HIGH POWER will automatically shut down.

CAUTION

When the brake release button is pressed, the quill (Joint 3) may drop to the bottom of its travel. To prevent possible damage to the equipment, make sure that the quill is supported while releasing the brake and verify that the end effector or other installed tooling is clear of all obstructions.

12

Figure 2-5. Robot base showing brake release button

13

AdeptOne User’s Guide

2.2 Dimensions

Figure 2-6. Dimensional Overview

14

Figure 2-7. AdeptOne Robot Working Envelope

15

AdeptOne User’s Guide

2.3 Performance Specifications

All specifications subject to change without notice.

Table 2-2. Performance Specifications

Reach

(Refer to Figures 2-6 and 2-7)

Maximum radial

Minimum radial

Vertical clearance (bottom of base to

end-effector flange)

Standard

7.7 in. stroke

- with maximum Joint 3 retraction

- with maximum Joint 3 extension

Optional

11.6 in. stroke

- with maximum Joint 3 retraction

- with maximum Joint 3 extension

Vertical Stroke

- Z direction (Refer to Figure 2-4)

31.5 in. (800 mm)

9.0 in. (229 mm)

34.52 in. (877 mm)

26.75 in. (679 mm)

30.52 in. (775 mm)

18.91 in. (480 mm)

7.7 in. (196 mm)

11.6 in. (295 mm)

Joint Rotation

(Refer to Figures 2-2, 2-3, and 2-4)

300°

294°

554°

Payload

(Including End Effector)

During operation

Inertia Load

(Maximum)

About Joint 4 axis - standard

20 lb (9.1 kg)

maximum*

96 lb-in

2

(0.28 N-m

2

)

1000 lb-in

2

(2.87 N-m

2

)

Force

Joint 3 downward force without payload 40 lb (18.2 kg)

Torque

Joint 4 torque

Cycle Time – 12 in. (305 mm)**

1 lb (0.45 kg)

13 lb (5.9 kg)

20 lb (9.1 kg)

60 lb-in (6.78 N-m)

0.9 sec

1.3 sec

1.7 sec

* Maximum possible using “J4 Tuner” software and running at reduced speed.

** The robot tool performs a continuous path motion consisting of all straight-line segments; 1 in. (25 mm) up, 12 in. (305 mm) over, 1 in. (25 mm) down, and returning along the same path. The endpoints of the cycle are approached in COARSE mode.

16

Table 2-2. Performance Specifications (continued)

Resolution

Joint 3 (vertical Z)

Joint 4 (tool rotation)

Repeatability

0.00078°

0.00312°

0.00013 in. (0.0033 mm)

0.047°

Joint 3 (vertical Z)

Joint 4 (rotational)

Accuracy in X/Y Plane

(at ±3° F)

With HPS over 17" x 17" area

Joint Speed

(maximum)

Joint 1

Joint 2

Joint 3

Weight

Joint 4

Robot without options

Design Life

±

0.001 in. (

±

0.025 mm)

±

0.002 in. ( ±0.050 mm)

±0.05°

±0.003 in. (±0.076 mm)

540°/sec

540°/sec

19.7 in./sec (500 mm/sec)

3600°/sec

400 lb (182 kg)

42,000 hours

2.4 Options

The AdeptOne is compatible with the following Adept options:

• Adept MC or Adept CC controller

• 11.6" vertical stroke

• 25 ft robot-to-controller cable set

• AdeptVision AGS-GV Systems

•

•

•

•

Variable Compliance Wrist (VCW)

Fifth Axis (Joint 5)

Force Sensing Module

High-accuracy Positioning System (HPS)

• Robot-mounted Camera Hardware • Clean room package (Class 10)

For information on the Fifth Axis, see Appendix A in this manual. Operating instructions and programs for the remaining options listed above are included in the user's guides supplied with each option.

17

AdeptOne User’s Guide

NOTES

18

INSTALLATION

3.1 Environmental and Facility Requirements

Facility Ambient Air Quality

Temperature: 41° to 122° F (5° to 50° C)

Relative Humidity: 5 to 95% non-condensing

Although the AdeptOne robot is designed to withstand a wide range of environmental conditions, it requires additional sealing when used in harsh environments. Examples of environments that require additional robot sealing include those with oil mist, coolant mist, water spray, or abrasive dust in the air. When a robot is used in such an environment, take the following steps to protect the robot:

• Seal the quill and outer link assembly with a quill bellows.

• Install gaskets on all access covers.

• Pressurize the robot slightly with clean, dry air.

Contact Adept Customer Service if you have questions concerning robot protection in such environments. Adept also offers the PackOne robot, which is designed to operate in harsher environments; call Adept for complete information on the PackOne.

Compressed Air

The AdeptOne requires clean, dry, oil-free compressed air at 80-110 pounds per square inch (psi) with a flow rate of 1 Standard Cubic Foot per Minute (SCFM). The AdeptOne uses compressed air to release the robot brakes and to provide air to the User air lines. End-effectors attached to the robot may require additional air flow. Insufficient air pressure or flow will allow the brakes to engage and will disable

HIGH

POWER

.

The AdeptOne has an air filter and moisture trap on its inlet air fitting.

The moisture trap should be emptied periodically; see Chapter 4 for cleaning instructions. If clean, dry air is not available, additional user-

supplied filtering is required

. The AdeptOne air connection inlet is a

19

AdeptOne User’s Guide

1/4-inch Industrial Interchange nipple located at the air filter at the base of the robot.

CAUTION

Failure to supply clean, dry, oil-free air may result in damage to mechanical, electrical, and pneumatic components inside the robot.

Electrical

The facility electrical supply must conform with specifications for the particular system controller, Adept MC or Adept CC. Refer to the appropriate controller user's guide for those specifications.

Robot Workcell Free Space

The AdeptOne working area (workcell) must allow for movement of the

AdeptOne within the area specified in Figure 2-7. Additional allowances must be added to accommodate any installed end-of-arm tooling and the calibration fixture.

Each robot is calibrated at the factory and the calibration data is stored on the Robot Signature Card (RSC) at the base of the robot. Some major robot repairs (such as replacing encoders) require recalibration of the robot. In order to recalibrate the robot, the calibration fixture must be installed on the base of the robot; see Figure 3-1. If adequate space is not provided in the workcell, the robot will have to be removed for recalibration.

Floor

The floor at the installation site must be concrete with a minimum thickness of 4.0 inches (102 mm) and must comply with all local codes.

The floor should be level so shims will not be needed to correctly install the robot.

Mounting Surface

Due to the very high torque (more than 200 ft-lb at the base) transmitted by the AdeptOne, the robot MUST be mounted to an extremely rigid structure. Any mounting structure vibration or flexing will seriously degrade robot performance. Adept recommends using either a mounting plate or a mounting spool. Both have proven reliable over extended periods of use. If another type of mounting structure is used, it must adequately resist vibration and flexure. Whichever mounting surface is selected, it must be supplied by the User.

20

Figure 3-1. AdeptOne with Calibration Fixture

21

AdeptOne User’s Guide

Figure 3-2. Mounting Hole Pattern (Robot-to-Plate/Spool)

Figure 3-3. Mounting Hole Pattern (Plate/Spool-to-Floor)

22

NOTE

Mounting the base on a surface other than the recommended steel plate (or spool) may make robot recalibration difficult. Make robot recalibration as easy as possible by designing a workcell that allows for mounting of the calibration fixture without extensive dismantling of the workcell.

Plate

The first method of mounting requires a flat steel plate and is mandatory if the robot is to be mounted directly to the facility floor. The mounting plate should conform to the following recommended specifications:

• Diameter: 24.0 inches (610 mm)

• Thickness:

• Mounting surface flatness:

1.0 inch (25 mm) within 0.01 inch (0.25 mm)

• Mounting hole pattern: as shown in Figures 3-2 and 3-3

Spool

The second method of mounting uses a spool. You can either make the spool yourself or purchase a prefabricated one. Refer to Figure 3-1 for an overview of an AdeptOne robot mounted on a spool. Two recommended sources for prefabricated spools are:

Interlake Bases

17480 Malyn Boulevard

Fraser, MI 48026

(313) 294-8120

American Grinding

2000 North Mango Ave.

Chicago, Il 60639

(312) 889-4343

The recommended design for a manufactured spool is a welded assembly consisting of three steel parts: top and bottom plates welded to a center column, as detailed in Figure 3-4.

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AdeptOne User’s Guide

Figure 3-4. Recommended Mounting Spool Specifications

3.2 Tool and Equipment Requirements

Common hand tools, plus the following items, are required to install the

AdeptOne and any options or end-effectors:

•

Drill motor, 1/2 inch drive

•

Masonry bit, 7/8 inch

•

Ratchet handle, 1/2 inch drive

•

Socket, 3/4 inch

24

•

Torque wrench, 1/2 inch drive, 100 foot-pound capacity

• Pallet jack (or forklift)

• Hydraulic lift with dual-leg sling (both rated for 700 pounds [320 kg] minimum)

• Mounting plate (or spool)

3.3 Unpacking and Inspection

Before Unpacking

Carefully inspect all shipping crates for evidence of damage during transit. Pay special attention to tilt and shock indication labels on the exteriors of the containers. If any damage is indicated, request that the carrier’s agent be present at the time the container is unpacked.

Upon Unpacking

Compare the actual items received (not just the packing slip) with your equipment purchase order and verify that all items are present and that the shipment is correct.

Inspect each item for external damage as it is removed from its container.

If any damage is evident, contact Adept at the numbers listed in Chapter

1.

Retain all containers and packaging materials. These items may become necessary to settle claims or, at a later date, to relocate equipment.

Repacking For Relocation

If the robot needs to be relocated, reverse the steps in the installation procedures that follow this section. Re-use all original packing containers and materials and follow all safety notes used for installation.

Improper packaging for shipment will void your warranty. Before unbolting the robot from the plate or spool, fold the outer arm against the

Joint 2 hardstops to help centralize the center of gravity. The robot must always be shipped in an upright orientation; specify this to the carrier if the robot has to be shipped.

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AdeptOne User’s Guide

3.4 Preparation For Installation

Complete the following steps before beginning the installation procedure.

1. Locate and set aside the “Robot-to-Plate/Spool” and “Plate/Spoolto-Floor” hardware kits. This hardware is typically packaged together and placed in the “Accessories” container.

2. Separate the following items from the “Robot-to-Plate/Spool” hardware kit:

•

Bolts, hex-head, 1/2-13 UNC x 2 inch (3 each)

• Washers, flat, 1/2 inch (3 each)

• Washers, lock, 1/2 inch (3 each)

3. Separate the following items from the “Plate/Spool-to-Floor” hardware kit:

•

Bolts, hex-head, 1/2-13 UNC x 4 inch (3 each)

•

Washers, flat, 1/2 inch (3 each)

• Washers, lock, 1/2 inch (3 each)

• Anchors, expansion bolt (3 each)

3.5 Installing a Mounting Plate

The following sequence details the installation of the robot-mounting plate to the floor. (See Figure 3-5.)

1. Drill and tap three 1/2-13 UNC-2B mounting holes, as shown in

Figure 3-2, for robot-to-plate attachment.

2. Drill three 5/8 inch (16 mm) diameter through holes, as shown in

Figure 3-3, for plate-to-floor anchoring.

3. Place the plate exactly where the robot is to be installed. Ensure that the plate is positioned so that the “footprint” for the robot is properly oriented relative to the workcell. Using the plate as a template, transfer the locations of the three plate-to-floor mounting holes directly to the floor.

4. Set the plate aside and drill three holes, 7/8 inch (22 mm) in diameter by 3.5 inches (90 mm) deep, in the floor at the locations identified in step 3.

26

Figure 3-5. Mounting Plate-to-Floor Installation Detail

5. Using a vacuum cleaner, remove all chips and debris from the holes

(and surrounding area) drilled in step 4.

6. Insert an expansion bolt anchor into each of the three holes in the floor. Ensure that the threaded end of each bolt anchor is toward the bottom of each hole, as shown in Figure 3-5.

7. Reposition the plate over the anchor holes in the floor using care to align the three plate-to-floor holes with the anchor holes. Ensure that the plate is positioned so that the “footprint” for the robot is properly oriented to the workcell.

8. Using a spirit level, verify that the top (mounting) surface of the plate is level. The surface must be horizontal within ±3 degrees. If the plate is not level, insert shims between the plate and the floor to bring the plate within specifications. The shims should be at least three inches (75 mm) in diameter and have cutouts provided to fit around the anchor bolts.

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AdeptOne User’s Guide

9.Insert a 1/2-13 x 4 inch bolt, fitted with a lock washer and a flat washer, through the holes in the plate into each of the three plate-to-floor anchor holes. Tighten the bolts to 40 ft-lb (54 N-m) of torque.

10. Re-check the robot mounting surface of the plate using the spirit level and re-shim as required to bring the mounting surface horizontal within ±3 degrees.

3.6 Installing a Mounting Spool

The following sequence details the installation of the robot-mounting spool to the floor. (See Figure 3-6.)

1. Drill and tap three 1/2-13 UNC-2B mounting holes (through), as shown in Figure 3-2, for robot-to-spool attachment.

2. Prepare the opposite flange of the mounting spool by drilling three

5/8-inch (16 mm) diameter through holes, as shown in Figure 3-3, for spool-to-floor anchoring.

3. Place the spool exactly where the robot is to be installed. Ensure that the spool is positioned so that the "footprint" for the robot is properly oriented to the workcell. Transfer the locations of the three spool-tofloor mounting holes directly to the floor.

4. Set the spool aside and drill three holes, 7/8 inch (22 mm) in diameter by 3.5 inches (90 mm) deep, in the floor at the locations identified in step 3.

5. Using a vacuum cleaner, remove all chips and debris from the holes

(and surrounding area) drilled in step 4.

6. Insert an expansion bolt anchor into each of the three holes in the floor. Ensure that the threaded end of each bolt anchor is toward the bottom of each hole, as shown in Figure 3-6.

7. Reposition the spool over the anchor holes in the floor taking care to align the three spool-to-floor holes with the anchor holes. Ensure that the spool is positioned so that the “footprint” for the robot is properly oriented to the workcell.

8. Using a spirit level, verify that the top (mounting) surface of the spool is level. The surface must be horizontal within ±3 degrees. If the spool is not level, insert shims between the spool and the floor to bring the spool within specifications. The shims should be at least three inches (75 mm) in diameter and have cutouts provided to fit around the anchor bolts.

9. Insert a 1/2-13 x 4 inch bolt, fitted with a lock washer and a flat washer, through the holes in the spool into each of the three spool-

28

to-floor anchor holes. Tighten the bolts to 40 ft-lb (54 N-m) of torque.

10. Re-check the robot-mounting surface of the spool using the spirit level and re-shim as required to bring the mounting surface horizontal within ±3 degrees.

Figure 3-6. Mounting Spool-to-Floor Installation Detail

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AdeptOne User’s Guide

3.7 Robot Installation

The following sequence details the installation of the robot to the mounting plate or spool.

1. Connect the hydraulic lift to the eyebolts at the top of the robot by means of the dual-leg sling. Take up any slack but DO NOT lift the robot at this time.

WARNING

Do not attempt to lift the robot at any points other than the eyebolts provided.

Do not attempt to extend the inner or outer links of the robot until the robot has been secured in position. Failure to comply could result in the robot falling and causing either personnel injury or equipment damage.

2. Remove the three bolts securing the robot base to the pallet. Retain these bolts for possible later relocation of the equipment.

3. Lift the robot and position it directly over the floor plate or spool.

WARNING

The robot may swing free if not lifted straight up. Stand clear of the robot at all times while it is supported by the lift.

4. Slowly lower the robot while aligning the base and the tapped mounting holes in the plate or spool.

5. Insert a 1/2-13 x 2 inch bolt fitted with both a lock washer and a flat washer through each of the three mounting holes in the robot base into the mounting plate or spool and torque to 65 ft-lb (88 N-m).

6. Disconnect the sling and remove the eyebolts from the arm. Retain the eyebolts for use during possible future relocation of the equipment.

30

3.8 Robot Connections

All interconnection points to the robot are located at the rear of the base; see Figure 3-7.

Robot to Controller

Electrical power and control signals are supplied to the robot by cables from the controller. The Arm Power and Arm Signal cables are connected to the robot at the rear of the base. Refer to the User's Guide for your specific controller (Adept MC or Adept CC) for instructions on robot-to-controller interconnect cabling, as well as complete instructions on connecting the controller to the facility electrical power.

Connecting Compressed Air Supply

The User must supply all tubing and fittings to plumb the facility air supply to the robot. The robot is supplied with an air filter with a standard 1/4-inch Industrial Interchange nipple.

The compressed air to the robot must meet the specifications listed in

Section 3.1.

Figure 3-7. Robot Base Showing Air Filter and Cable Connector Locations

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AdeptOne User’s Guide

3.9 Compressed Air Lines In the Robot

Solenoid Valve Assembly

The solenoid valve assembly (under the Joint 2 cover) consists of two independent valves (Valve #1 and Valve #2) on a common manifold. The manifold supplies air at the user’s line pressure (80 psi minimum). Each valve has two output ports, A and B. The output ports are arranged so that when Port A is pressurized, Port B is not pressurized. Conversely, when Port B is pressurized, Port A is not. In the AdeptOne robot, the air lines from Port A on each valve are plugged at the factory (at the tower assembly, see Figure 3-8) and the lines from Port B are routed out to the flange and are used for the User Open and Close lines; see the description of the user air lines in next section.

Mounting holes are provided to install a four-position manifold in place of the existing two-position manifold under the Joint 2 upper cover.

Contact Adept Field Service for information on this installation.

Figure 3-8. User Connections in the Robot

32

User Air Lines

The User Open and Close air lines are the two 5/32" air lines that run between the solenoid valve assembly and the user flange at the lower end of the quill. These lines are plugged at the flange end, and are labeled

Port B Valve #1 and Valve #2. They are controlled by the V/V

+ commands OPEN(I), CLOSE(I), and RELAX(I), or the software signals

2030 and 2031; see Table 3-1. (See the V and V

+

Reference Guide for more information.)

There are two extra user air lines that run from the solenoid valve assembly to the outer link tower assembly; they are labeled Port A Valve

#1 and Port A Valve #2. These extra lines are plugged at the factory, but can be used if you need two lines from each valve instead of one; see

Figure 3-8.

After initial installation, it is a good idea to check the positive pressure on the open and close air lines to verify that they are installed as shown in

Table 3-1.

State

“Open”

“Closed”

“Relaxed”

Table 3-1. User Air Line Command Summary

Pneumatic Action on Port B*

Pressure at Valve 1 on

Port B, no pressure at Valve 2 on Port B**

Pressure at Valve 2 on

Port B, no pressure at Valve 1 on Port B**

No pressure at either

Valve 1 or 2 on

Port B**

V/V

+

Command

DO OPENI

(or)

SIGNAL -2030, +2031

DO CLOSEI

(or)

SIGNAL +2030, -2031

DO RELAXI

(or)

SIGNAL -2030, -2031

MCP Procedure

In World, Tool, or

Joint state, press T1 and plus speed bar

In World, Tool, or

Joint state, press T1 and minus speed bar

In Free state, press T1

*Pneumatic action on Port A will be the opposite of Port B.

**No pressure indicates that the valve is connected to the return exhaust.

Spare Air Line

A “spare” air line, 1/8", is incorporated into the robot to allow for User options. This line runs from the base of the robot up to the area near the outer link card in the outer link. The line is not supplied with connection fittings at either end. At the base, the end of the air line can be routed through either one of the access holes capped with removeable plastic plugs (Figure 3-8).

To gain access to the spare air line at the base, remove eight cap-head screws that secure the base top cover, then lift and turn the cover out of the way. Be careful not to disturb exposed parts and wiring when top

33

AdeptOne User’s Guide

cover is off. At the outer link location, the air line can be accessed by removing the outer link access cover.

3.10 Installing End-Effectors

Providing an end-effector or other end-of-arm tooling is the responsibility of the User. An end-effector can be attached to the flange by using a ring clamp (supplied) or four 8-32 screws (supplied). For details of the flange mounting surface refer to Figure 3-11.

Clamp-mounted End-Effector

The following procedure describes the installation of a typical endeffector using the ring clamp. (Refer to Figure 3-9.)

1. Disconnect the air supply to the robot.

2. Remove the plugs from the "Open" and "Close" air lines where they protrude from the quill flange.

3. Place the ring clamp over the quill flange.

Figure 3-9. Clamp-mounted End-Effector Installation

4. Install the "Open" and "Close" air lines onto the appropriate fittings on the end-effector.

34

5. Mate the end-effector flange to the quill flange. Rotate the endeffector until its key aligns with the keyway in the quill flange, then place the ring clamp over both flanges and tighten the clamp screw.

6. Test the operation of the end-effector to ensure that the Open and

Close functions are not reversed.

Screw-mounted End-Effector

The following procedure describes installing an end-effector using four screws. (See Figure 3-10.)

1. Disconnect the air supply to the robot.

2. Remove the plugs from the "Open" and "Close" air lines where they protrude from the quill flange.

3. Install the "Open" and "Close" air lines onto the appropriate fittings on the end-effector.

Figure 3-10. Screw-mounted End-Effector Installation

4. Mate the end-effector flange to the quill flange. Rotate the endeffector until its key aligns with the keyway in the quill flange.

35

AdeptOne User’s Guide

5. Insert four 8-32 screws through the mounting holes and tighten.

Recommended torque is 15 in-lb (1.69 N-m). If the screws protrude slightly through the flange, align the cutouts in the Joint 3 hardstop

(located just above the quill flange) to accommodate the screw tips.

CAUTION

Do not allow the mounting screws to protrude up into the hardstop any farther than the cutouts, because this can prevent proper seating of the flange against the hardstop.

Improper seating against the hardstop will prevent the robot from calibrating properly and will cause all of the previously taught robot locations to have the wrong height.

6. Test the operation of the end-effector to ensure that the Open and

Close functions are not reversed.

36

Figure 3-11. Quill Flange Dimensions

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AdeptOne User’s Guide

3.11 User Signal and Voltage Lines

User signal and voltage lines are available at the User connector located on the Tower assembly of the AdeptOne. The Tower assembly is located under the quill cover (refer to Figure 3-12). The pin-out for the User connector is shown in Table 3-2.The facilities on the User connector are provided to help users integrate their end-effector requirements with a minimum of external cables and hardware. However, some users prefer to provide their own external cabling and supplies. The cables would be routed along the outside of the robot arm, directly to the I/O ports on the controller. External facilities will generally be easier to maintain and trouble-shoot. Be sure to follow the guidelines presented in Section 1.5 on Robot Modifications.

USR1 Through

USR5

USR1 through USR5 line pairs provide a convenient wiring run from the robot Tower to the controller. These lines terminate at the User connector on the Tower assembly and can be used to connect limit switches or similar digital devices to the digital interface of the controller. Refer to your controller user's guide for further information on termination of these lines within the controller. Use of these lines should be limited to a maximum of 24 VDC at 2 Amps.

CAUTION

USR1 through USR5 lines are routed through the robot harness in close proximity to robot control signals. To ensure long life, these lines are constructed from 28 AWG high-strand-count wires and are not designed to carry high current or high voltage. These lines should be limited to a maximum of 24 VDC at 2 Amps. To minimize coupling with robot control signals in adjacent harnesses, the User should minimize voltage transients and maintain a current balance in each +/- pair. Exceeding these recommendations could couple noise onto the robot control lines and cause robot motion errors.

Spare Solenoid Drivers

Two spare solenoid drivers are provided on the User connector; see SIG

2025 and SIG 2026 in Table 3-2. These are directly switchable from V or

V

+ by utilizing software signals 2025 and 2026. Refer to the SIGNAL command in the V and V

+

Reference Guide for additional information.

Each driver is designed to handle 12 VDC solenoids at up to 500 mA, similar to the hand OPEN/CLOSE solenoids. To overcome the problem of dirt buildup at the solenoids, special circuitry has been incorporated to

38

provide a momentary 24 V initial pulse to the solenoid to break any stiction, dropping to 12 V for holding.

Some solenoid manufacturers include a transient-suppression diode across the leads of their solenoids. If such a diode is installed on the solenoid you have selected, verify that the polarity is correct. A reverse installation will short the diode across the driver circuitry. The User is cautioned to use solenoids similar in design to the ones used for the hand

OPEN/CLOSE lines and to carefully check the wiring polarity before applying power.

CAUTION

The solenoid driver hardware has no current limiting capability and will attempt to drive a solenoid with as much current as the impedance of the solenoid will accept.

As a result, if the User accidently shorts the solenoid +/- leads together, the driver circuit will "over-current" and fail. The robot signature card in the base enclosure will then have to be repaired before that User solenoid can be reused.

Figure 3-12. User Connector Location on the Tower Assembly

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AdeptOne User’s Guide

DC Power

The User connector provides limited DC power to drive User end-of-arm hardware such as indicators, small motors, or other analog devices. 12

VDC, 12RTN, and FRAME ground are available. A -12 VDC signal is available by modifying the Outer Link card; see the procedure following

Table 3-2.

CAUTION

Power lines (like User lines) are routed in close proximity to the robot harness. To ensure their long life, they are constructed of 26 AWG high-strand-count wire and are not designed to carry high current or voltage. To minimize coupling with robot control signals in the harness, try to minimize power demand transients on these lines.

Table 3-2. Tower User Connector Pinouts

Pin No.

1

2

3

4

5

Signal

Usr1+

Usr1-

Usr2+

Usr2-

Usr3+

6

7

Usr3-

+12V

8 12V Rtn

9 NC

10 NC

11 Usr4+

12 Usr4-

13 FRAME

14

15

16

17

18

19

Comments

User signal, terminated at controller XIB

User signal, terminated at controller XIB

User signal, terminated at controller XIB

User signal, terminated at controller XIB

User signal, terminated at controller XIB

User signal, terminated at controller XIB

Uncommitted supply, 1 A max

Uncommitted supply, 1 A max

User signal, terminated at controller XIB

User signal, terminated at controller XIB

SIG 2026+ (12V)* Solenoid drive supply OR -12V Rtn (select on OLC)

SIG 2026- (Rtn)* Solenoid drive return OR -12V (select on OLC)

SIG 2025+ (12V)* Solenoid drive supply

SIG 2025- (Rtn)* Solenoid drive return

Usr5+

Usr5-

User signal, terminated at controller XIB

User signal, terminated at controller XIB

Connector: 19-pin MicroMiniature Connector, ITT Cannon 2DE19S

Mates with ITT Cannon Connector 2DE19P (supplied in accessory kit)

*

See Caution on page 39.

40

Optional -12 VDC Procedure

You can have -12 VDC and return on the User connector by cutting two traces and adding two jumpers on the Outer Link Card (OLC). By making this modification you lose the solenoid driver on SIG 2026+ and

2026-.

Figure 3-13 shows the location of the User Option (UO) jumper header on the OLC. You access the OLC by removing the cover panel on the under side of the outer link.

Figure 3-13. User Option Jumper Header on OLC

1. Locate the UO jumper header on the OLC, and cut the trace between pins 3 and 5, then cut the trace between pins 4 and 6.

2. Solder wire jumpers between pins 1 and 3, and between pins 2 and 4.

3. You now have -12 VDC (pin 15) and return (pin 14) at the User connector.

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AdeptOne User’s Guide

3.12 Outer Link Mounting Holes

The mounting holes on the top side of the outer link can be used to mount user equipment See the section on Robot Modifications in

Chapter 1 for information on limitations for modifications. Figure 3-14 shows the dimensions of the mounting holes.

Figure 3-14. Mounting Holes on Top Side of Outer Link

42

MAINTENANCE

4.1 Introduction

The AdeptOne robot requires very little maintenance due to its directdrive design. Joints 1 and 2 need no maintenance at all. This chapter describes the preventive maintenance procedures that are required to keep the robot operating properly. See Table 4-1 at the end of this chapter for a summary of the preventive maintenance procedures and some rough guidelines on frequency.

4.2 Lubrication

The Joint 3 quill shaft requires periodic lubrication. The frequency of lubrication will depend on the operating environment and amount of usage. Initially, check the quill once a week, recording the results with the intent of producing a schedule appropriate to the particular system, its environment, and usage.

To check for adequate lubrication at the Joint 3 quill, run a finger along the quill. A thin film of grease should be present. If the shaft is dry, it needs lubrication. Adept uses and recommends:

Dow Corning MOLYKOTE BR2 PLUS, a molybdenum disulfide based grease

(Dow catalog number 89570-81)

CAUTION

Using improper lubrication products on the AdeptOne can cause damage to the robot.

Lubricating the Upper Quill Shaft

Lubrication of the robot requires that the quill be moved while

HIGH

POWER (ARM POWER)

is off. Use the brake release button at the rear of the base to release the brake allowing manual quill movement.

43

AdeptOne User’s Guide

CAUTION

When the brake release button is pressed, the quill could drop to the bottom of its travel. To prevent possible damage to the equipment, make sure that the quill is supported while releasing the brake and verify that installed tooling is clear of all obstructions.

HIGH POWER

to the robot.

2. Remove the quill cover. Press the brake release button and move the quill to its fully raised position. Inspect the upper quill shaft and remove any excess or accumulated grease.

3. Use a grease syringe to apply five lines of grease vertically on the exposed quill shaft. Each line should run from top to bottom and be evenly spaced around the shaft.

Figure 4-1. Upper Quill Shaft

44

Lubricating the Lower Quill Shaft

1. Move Joint 3 to the bottom of its travel.

2. The Joint 3 seal is a soft, rubber lip seal located as shown in Figure 4-

2. Gently insert the tip of the syringe applicator underneath the seal and apply grease around the entire circumference of the shaft.

3. Apply three thin lines of grease vertically on the shaft with each line running from top to bottom and evenly spaced around the lower shaft.

4. With your fingers, spread the grease into a thin film covering the entire shaft surface, including the “V” groove.

5. Move Joint 3 slowly from the bottom to the top of its travel several times, then leave it in the middle of its travel. Use a cloth to wipe away any excess grease on the shaft or at the seal.

6. Replace the quill cover.

Figure 4-2. Lower Quill Shaft and Lip Seal Location

4.3 Draining Moisture from the Air Filter

The air filter on the compressed air inlet at the robot base has a moisture trap that should be emptied periodically, depending on the quality of the air supply and the frequency of usage. The procedure to empty the trap is done with the air supply connected. To empty the trap, use a rag to push up on the bottom of the air filter.If you have to empty water from the filter housing frequently, you should investigate the water content in your compressed air supply and consider using an air dryer. Moisture

45

AdeptOne User’s Guide

inside the robot can cause damage to mechanical, electrical, and pneumatic components.

4.4 Check Mounting Bolt Tightness

The robot mounting bolts should be checked on a periodic basis to make sure they have not worked themselves loose. Also check all cover plate screws and the arm power and arm signal cables for tightness.

Table 4-1. Recommended AdeptOne Preventive Maintenance Schedule*

Item Recommended Schedule (hours)

Lubricate the upper and lower quill shaft Every 3 months or ~1000 hours

Drain air filter moisture trap

Check all screws in cover plates and robot mounting stand

Monthly

Monthly

Check the arm signal and arm power cables

Monthly

*The frequency of these procedures will depend on the particular system, its operating environment, and amount of usage. Use the times in Table 4-1 as guidelines and modify the schedule as needed.

46

FIFTH AXIS OPTIONS

A.1 Introduction

Fifth Axis Option

The fifth axis, also known as Joint 5, is a servo pitch option for Adept robots. The fifth axis allows the robot to position end-of-arm tooling between +90° and -90° from vertical. The fifth axis is fully integrated into the robot system. The servo mechanism is contained within the robot quill, and the control hardware is located in the robot controller.

Movement of the fifth axis is controlled by the standard Adept system software, either V or V

+

.

Pneumatic End-Effector

Besides servo pitch option mentioned above, a two-position pneumatic end-effector is available on a semi-custom basis. This pneumatic endeffector is available in two sizes. Call Adept Applications for complete information; the phone number is listed in Chapter 1.

A.2 Specifications

Maximum Travel

Maximum Speed

Table A-1. Fifth Axis Specifications

±91° (0° reference - vertically downward)

180° in 0.3 seconds

Maximum Payload

Resolution

Repeatability

7 lb (3.18 kg)

±

0.0057° (0.0002" [

±

0.005 mm] at the fifth-axis flange)

±

0.086° (

±

0.003" [

±

0.076 mm] at the fifth-axis flange)

Static Torque

Mounting Flange

45 lb-in. (0.52 kg-m)

Standard Adept tool flange without center hole

Axis center-to-flange offset

2" (50 mm)

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AdeptOne User’s Guide

A.3 Installation

The fifth axis can be installed either at the factory or by an Adept

Customer Service Engineer at the user's site. Call Customer Service for information on installing the fifth axis.

A.4 Operation

Installing End-effectors

The fifth-axis end-effector tool flange will accept any "flat-back" endeffector compatible with the standard Adept flange (see Figure A-1). The end-effector can either be bolted on or secured with the standard Adept ring clamp. A 1.749" diameter by 0.100" high alignment pad on the endeffector is accommodated, but any utilities must be side ported.

The fifth axis includes two air line fittings and a user electrical receptacle for interfacing to end-of-arm tooling; see Figure A-1.

J5 User Cable Connector

A cable with a six-pin connector on one end (Adept part number 10845-

24950) is supplied with the fifth axis. This cable is designed to mate with the J5 User cable receptacle located between the two air fittings (see

Figure A-1). The table below shows the connector pin identification and the corresponding pin number at the User connector on the AdeptOne tower assembly. Pin cavities 1, 5, 9, and 10 are not used. The connector is polarized and will not mate if incorrectly aligned.

Table A-2. J5 User Cable Connector Pin Identification

J5

Connector

Pin #

J5 Connector

Wire Color Signal

Pin # at User

Connector on

Tower Assy

48

Figure A-1. Fifth-Axis End-Effector Mounting Details

Programming Information

The fifth axis is a fully integrated robot joint and treated the same as the other joints. Like Joints 1 through 4, the fifth axis can be controlled by either the manual control pendant (MCP) or by program instructions from the controller. Refer to the controller User's Guide for information on the MCP and the V and V

+

Reference Guide for robot programming instructions.

49

AdeptOne User’s Guide

A.5 Maintenance and Troubleshooting

The fifth axis requires no regular maintenance or lubrication.

Checking Flange Position

The fifth-axis flange surface should be at 90° to the side of the gear box when the Joint 5 value is zero. A substantial fifth-axis crash could cause the flange position to slip. Use a machinist square to check for possible slippage when the Joint 5 value is zero. If the flange is not at 90°, contact

Customer Service at the number listed in Chapter 1. Do not attempt to force the joint back to its proper position.

50

INDEX

Air filter draining moisture, 45

Air quality facility requirements, 19

Application information, 3

Brake-release button, 12

Brakes description, 12 releasing for manual movement, 12

Cables arm power, 31 arm signal, 31

Calibration fixture, 20

Compressed air extra lines, 33 installation, 31 requirements, 19 spare line inside robot, 34

User air lines, 33

Controller

High Power indicator, 2

Customer Service Assistance phone numbers, 2

DC power availability on User connector, 40

Dimensional overview, 14

End-effector installation clamp-mounted, 34 screw-mounted, 35

Envelope working, 15

Fifth Axis checking flange position, 50 installation, 48 installing end effectors, 48

J5 User cable connector, 48 specifications, 47

Hardstops description, 11 specifications, 12

Installation floor requirements, 20 mounting surface, 20 preparation for, 26 required tools, 24

International Customer Assistance, 3

Joint motion

Joint 1, 7

Joint 2, 7

Joint 3, 10

Joint 4, 10

Lefty configuration, 8

Limiting joint travel hardstops, 11 softstops, 11

Lubrication lower quill shaft, 45 type of grease, 43 upper quill shaft, 43

Maintenance lubrication, 43 schedule, 46

Modifications acceptable, 5 unacceptable, 5

Moisture trap on air inlet, 20

Mounting hole pattern plate or spool to floor, 22 robot to plate or spool, 22

Mounting holes on outer link, 42

Mounting plate

51

installation, 26 specifications, 23

Mounting spool installation, 28 specifications, 23

Optional -12 VDC procedure, 41

Quill vertical stroke, 10

Quill flange dimensions, 34

Repacking for relocation, 25

Righty configuration, 8

Robot connection to controller, 31 dimensions, 14 installation, 30 joint locations, 7 modifications, 5 optional equipment, 17 performance specifications, 16 working envelope, 15

AdeptOne User’s Guide

Safety, 3-4

Softstops description, 11 specifications, 12

Solenoid drivers

2025, 2026 on User connector, 38

Solenoid valve assembly, 32

Training information, 3

Unpacking robot crate, 25

User connector location, 38 pinouts, 40

USR1 to USR5 lines location, 38 max current, 38

Workcell free space, 20

52

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Adept Technology, Inc.

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150 Rose Orchard Way

San Jose, CA 95134

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AdeptOne User's Guide

2

Chapter 1 – General Information

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AdeptOne User's Guide

00840-10100, Rev. C

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